Flexible fuel cell power system

ABSTRACT

A flexible fuel cell power system comprising one or more fuel cell cartridges (which contain fuel cell modules) connected to a fuel cell system is provided. The components of the flexible fuel cell power system may be placed on a shared backbone with flexible joints, and may be made of flexible materials so that the entire system can be worn by a human being.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a Continuation of U.S. patent applicationSer. No. 15/266,866 filed Sep. 15, 2016, which is a Continuation ofinternational patent application PCT/US2015/021324 filed Mar. 18, 2015,which claims priority to Provisional patent application 61/955,351 filedMar. 19, 2014, the disclosures of which are incorporated by reference intheir entirety.

FIELD OF THE DISCLOSURE

This disclosure relates to a flexible fuel cell power system that can beconfigured to a variety of uses.

BACKGROUND

Fuel cells are electrochemical energy conversion devices that convert anexternal source fuel into electrical current. Many fuel cells usehydrogen as the fuel and oxygen (typically from air) as an oxidant. Theby-product for such a fuel cell is water, making the fuel cell a verylow environmental impact device for generating power.

Fuel cells compete with numerous other technologies for producing power,such as the gasoline turbine, the internal combustion engine, and thebattery. A fuel cell provides a direct current (DC) voltage that can beused for numerous applications including stationary power generation,lighting, back-up power, consumer electronics, personal mobilitydevices, such as electric bicycles, as well as landscaping equipment,and other applications. There are a wide variety of fuel cellsavailable, each using a different chemistry to generate power. Fuelcells are usually classified according to their operating temperatureand the type of electrolyte system that they utilize. One common fuelcell is the polymer exchange membrane fuel cell (PEMFC), which useshydrogen as the fuel with oxygen (usually air) as its oxidant. It has ahigh power density and a low operating temperature of usually below 80°C. These fuel cells are reliable with modest packaging and systemimplementation requirements.

The challenge of hydrogen storage and generation has limited thewide-scale adoption of PEM fuel cells. Although molecular hydrogen has avery high energy density on a mass basis, as a gas at ambient conditionsit has very low energy density by volume. The techniques employed toprovide hydrogen to portable applications are widespread, including highpressure and cryogenics, but they have most often focused on chemicalcompounds that reliably release hydrogen gas on-demand. Three broadlyaccepted mechanisms used to store hydrogen in materials are absorption,adsorption, and chemical reaction.

In absorptive hydrogen storage for fueling a fuel cell, hydrogen gas isabsorbed directly at high pressure into the bulk of a specificcrystalline material, such as a metal hydride. Metal hydrides such asMgH₂, NaAlH₄, and LaNi₅H₆, can be used to store the hydrogen gasreversibly. However, metal hydride systems often suffer from poorspecific energy (i.e., a low hydrogen storage to metal hydride massratio) and poor input/output flow characteristics. The hydrogen flowcharacteristics are driven by the endothermic properties of metalhydrides (the internal temperature drops when removing hydrogen andrises when recharging with hydrogen). Because of these properties, metalhydrides tend to be heavy and require complicated systems to rapidlycharge and/or discharge them. For example, see U.S. Pat. No. 7,271,567for a system designed to store and then controllably release pressurizedhydrogen gas from a cartridge containing a metal hydride or some otherhydrogen-based chemical fuel. This system also monitors the level ofremaining hydrogen capable of being delivered to the fuel cell bymeasuring the temperature and/or the pressure of the metal hydride fuelitself and/or by measuring the current output of the fuel cell toestimate the amount of hydrogen consumed.

In adsorption hydrogen storage for fueling a fuel cell, molecularhydrogen is associated with the chemical fuel by either physisorption orchemisorption. Chemical hydrides, such as lithium hydride (LiH), lithiumaluminum hydride (LiAlH₄), lithium borohydride (LiBH₄), sodium hydride(NaH), sodium borohydride (NaBH₄ or “SBH”), and the like, are used tostore hydrogen gas non-reversibly. Chemical hydrides produce largeamounts of hydrogen gas upon reaction with water as shown below:

NaBH₄(s)+4H₂O(l)→4H₂(g)+NaBO₂*2H₂O(aq)

To reliably control the reaction of chemical hydrides with water torelease hydrogen gas from a fuel storage device, a catalyst must beemployed along with control of the water's pH. Additionally, thechemical hydride is often embodied in a slurry of inert stabilizingliquid to protect the hydride from early release of its hydrogen gas.

In chemical reaction methods for producing hydrogen for a fuel cell,often hydrogen storage and hydrogen release are catalyzed by a modestchange in temperature or pressure of the chemical fuel. One example ofthis chemical system, which is catalyzed by temperature, is hydrogengeneration from ammonia-borane by the following reaction:

NH₃BH₃→NH₂BH₂+H₂→NHBH+H₂

The first reaction releases 6.1 wt. % hydrogen and occurs atapproximately 120° C., while the second reaction releases another 6.5wt. % hydrogen and occurs at approximately 160° C. These chemicalreaction methods do not use water as an initiator to produce hydrogengas, do not require a tight control of the system pH, and often do notrequire a separate catalyst material. However, these chemical reactionmethods are plagued with system control issues often due to the commonoccurrence of thermal runaway. Such a heat driven system depending ondecomposition of the material may also not extract all availablehydrogen completely and cleanly, and usable hydrogen is often stillbonded to the byproduct and wasted in the reaction. See, for example,U.S. Pat. No. 7,682,411, for a system designed to thermally initializehydrogen generation from ammonia-borane and to protect from thermalrunaway. See, for example, U.S. Pat. Nos. 7,316,788 and 7,578,992, forchemical reaction methods that employ a catalyst and a solvent to changethe thermal hydrogen release conditions.

As the technology for fuel cell power systems improves, the applicationsand demand expand, which cannot be met by the existing state of the art.For example, modern combat soldiers need power systems that arelightweight, safe, flexible and easy to transport while meeting certainenergy requirements. Other professions such as technicians andprofessionals also have a need for power systems that are lightweight,safe, flexible and easy to transport while meeting other energyrequirements.

As such, there is a need for an improved fuel cell power system that isflexible, lightweight, safe, and easy to transport while meeting variousenergy requirements.

DISCLOSURE

The present disclosure provides aspects of flexible fuel cell powersystems comprising a fuel cell cartridge and a fuel cell system. Inexemplary implementations, the flexible fuel cell power systems comprisea fuel cell cartridge comprising a plurality of fuel cell modules, afuel cell system, and a platform, wherein said fuel cell cartridge andsaid fuel cell system are attached to said platform, and wherein saidplatform includes bendable joints or flexures which permit said platformto be flexible.

The present disclosure provides shared balance of plant platforms for aflexible fuel cell power systems comprising a platform having bendablejoints or flexures which permit said platform to be flexible, a fuelcell cartridge comprising a plurality of fuel cell modules, a fuel cellsystem comprising a fuel cell stack and a balance of plant, where thebalance of plant comprises one or more hydrogen gas fluid lines, one ormore water fluid lines, and one or more of a purge valve, a stack airblower, a system controller PCB assembly, a heat sink, a micropump, afuel selector, a battery, and an output/comms connector, wherein saidfuel cell cartridge and said fuel cell system are attached to saidplatform, wherein at least one of the hydrogen gas fluid lines and waterfluid lines of the balance of plant are shared by the plurality of fuelcell modules, and wherein the modules are hot swappable.

DRAWINGS

The summary, as well as the following detailed description, is furtherunderstood when read in conjunction with the appended drawings. For thepurpose of illustrating the disclosure, there are shown in the drawingsexemplary implementations of the disclosure; however, the disclosure isnot limited to the specific methods, compositions, and devicesdisclosed. In addition, the drawings are not necessarily drawn to scale.In the drawings:

FIG. 1 illustrates aspects of a NaSi and NaBH₄ hybrid mix according tothe present disclosure.

FIG. 2 is a chart comparing the hydrogen generation characteristics ofNaSi, NaBH₄ (“SBH”), and NaSi/NaBH₄ hybrid mixture.

FIG. 3 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 4 illustrates aspects of a state-of-charge indicator of a fuel cellpower system in an exemplary implementation of the present disclosure.

FIG. 5 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 6 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 7 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 8 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 9 illustrates aspects of the interior of the fuel cell system in anexemplary implementation of the present disclosure.

FIG. 10 illustrates aspects of the connections in a fuel cell powersystem in an exemplary implementation of the present disclosure.

FIG. 11 illustrates aspects of the collapsible water and expandable fuelbags in a fuel cell power system in an exemplary implementation of thepresent disclosure.

FIG. 12 illustrates aspects of a fuel cell power system in an exemplaryimplementation of the present disclosure.

FIG. 13 illustrates aspects of a punching operation of a flexible tubesystem and an exemplary implementation of the same.

FIG. 14 illustrates aspects of canisters in an exemplary implementationof the present disclosure.

All reference numerals, designators, and call-outs in the figures andAppendix are hereby incorporated by this reference as fully set forthherein. The failure to number an element in a figure is not intended towaive any rights, and unnumbered references may also be identified byalpha characters in the figures and Appendix.

FURTHER DISCLOSURE

The present disclosure may be understood more readily by reference tothe following detailed description taken in connection with theaccompanying figures and examples, which form a part of this disclosure.It is to be understood that this disclosure is not limited to thespecific devices, methods, applications, conditions or parametersdescribed and/or shown herein, and that the terminology used herein isfor the purpose of describing particular exemplars by way of exampleonly and is not intended to be limiting of the claimed disclosure. Also,as used in the specification including the appended claims, the singularforms “a,” “an,” and “the” include the plural, and reference to aparticular numerical value includes at least that particular value,unless the context clearly dictates otherwise. The term “plurality”, asused herein, means more than one. When a range of values is expressed,another exemplar includes from the one particular value and/or to theother particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another exemplar. All ranges areinclusive and combinable.

It is to be appreciated that certain features of the disclosure whichare, for clarity, described herein in the context of separate exemplar,may also be provided in combination in a single exemplaryimplementation. Conversely, various features of the disclosure that are,for brevity, described in the context of a single exemplaryimplementation, may also be provided separately or in anysubcombination. Further, references to values stated in ranges includeeach and every value within that range.

In one aspect, the present disclosure provides flexible fuel cell powersystems comprising a fuel cell cartridge and a fuel cell system. Inexemplary implementations, the flexible fuel cell power systems comprisea fuel cell cartridge comprising a plurality of fuel cell modules, afuel cell system, and a platform, wherein said fuel cell cartridge andsaid fuel cell system are attached to said platform, and wherein saidplatform includes bendable joints or flexures which permit said platformto be flexible.

In exemplary implementations, a plurality of fuel cell modules making upa fuel cell cartridge are connected to a fuel cell system. In suchimplementations, each of the individual fuel cell modules can beindependently connected to a shared flexible backbone. Each ofindividual fuel cell cartridges may further be replaced on its own. Theplurality of fuel cell modules may be arranged in an array.

In exemplary implementations the flexible fuel cell power systems can beformed by using bendable joints and/or soft material selection for thefuel cell cartridge and/or the fuel cell system. For example, the systemcan be constructed from an array of hydrolysis cartridges interlocked ona “chain” via flexures integrated from a shared back plane, thinlyconstructed spine, or any variation of the aforementioned. The flexurescan be customized to provide sufficient and realistic degrees ofbendability in between each cartridge without compromising structuralintegrity and/or pinching gas and water fluid paths. A shared waterinput/gas output line to the fuel cell modules integrated onto thisshared element provides for detachment and refueling withoutinterrupting power delivery. The array of modules can be configured toeither be engaged in series or simultaneously depending on hydrogengeneration demands of the fuel cell system. The system could also bepartially or entirely constructed from malleable, elastomeric or veryflexible material types, such as Mylar, which could inherently adhere toa wearer's body so that a person such as a soldier or technician canwear or carry the flexible fuel cell power system. The cartridge mayconsist of multiple flexible layers accomplishing different functionslike chemical containment, water containment, or physical handling.Alternatively, the flexible fuel modules array could be formed by hingedor elastic joints connecting the modules directly to each other,irrespective of a backbone, with interconnection plumbing achieved viaeither discrete cables and/or hoses, or a highly-integrated plumbing andwiring assembly connected to each module in the array.

In exemplary implementations, the flexible fuel cell power systems ofthe present disclosure can be adjusted depending on what is needed. Forexample, for applications that require high structural support andrigidity (e.g., high pressure/impact resistance and/or high hydrogenpressure delivery into the fuel cell system), the entire hydrolysisreaction may be contained in hard housings. Individual thin planarmodules may be attached to a common spine and can bend viaflexures/flanges between each module.

In other exemplary implementations, the flexible fuel cell power systemscan be designed for medical structural support and rigidity (e.g.,structural support via limited inflexible pieces and basic rigidity viastructures such as integrated beam supports or a skeleton). An exampleof such a system is a lightweight system comprising individually stackedfuel and water pouches that can hang from the shared water/gas line.Fueling can be performed via a puncturing motion. For passive waterinjection, this configuration can be initiated via integration of asimple inflexible lid that compresses the water bag for pressurization.Refueling would involve replacement of the pouches only. The lightweightmaterial of the cartridge body also facilitates storage andtransportation of multiple spares.

In further implementations, the flexible fuel cell power systems can bedesigned for low structural support and rigidity (e.g., low pressureinput fuel cells). These configurations provide structural support vialimited inflexible pieces and are almost entirely elastic and physicallypliant. A bladder system may be used in some implementations. Volumeexchange can be accomplished via a collapsible water bladder emptyingout into a surrounding fuel bladder that is expanding into the samevolume with byproduct formation and water input. All systemconfigurations proposed herein are capable of integration with bothactive and passive controls for water injection. Similarly, optimizationof all usable volume in the hydrogen cartridge can be achieved by activeor passively driven water and waste byproduct volume exchange.Volume-exchange can also be achieved by passively utilizing acontinuously collapsible water bladder as the aforementioned or via adialed-in pressure differential in the system itself to compress thewater compartment when the system calls for it In some instances, wateris purged from the system sporadically to lower delivery pressure, andthe fuel/waste compartment, at a higher pressure, expands into the newlyavailable space at set intervals.

The Fuel Cell Cartridge

The purpose of the fuel cell cartridges is to produce or generatehydrogen, which will be delivered to the fuel cell system. Power isgenerated in the fuel cell systems using any fuel cell technology knownin the art which uses hydrogen as the fuel.

The reactant fuel materials used in the present disclosure react quicklyand cleanly with any water solution; the product of the hydrolysisreaction is high-purity, humidified hydrogen, which is the preferredfuel for a proton exchange membrane (PEM) fuel cell. No PEM catalystpoisons or stream diluents are formed from the reaction (such as CO andCO₂) that might be detrimental to fuel cell performance.

U.S. Patent Publication No. 2010/0247426, which is herein incorporatedby reference in its entirety, describes useful fuel cell cartridges thatmay be used in the present disclosure. In exemplary implementations, thefuel cell cartridges comprise a reactor of various designs in which anaqueous solution is introduced to a reactant fuel material to generatehydrogen. The reactant fuel material may be a stabilized alkali metalmaterial (e.g., sodium silicide, sodium-silica gel) and can includeadditional reactants such as sodium borohydride (NaBH₄ or “SBH”), and/orammonia borane, and the like. Other conventional reactant fuel materialssuch as Group 1 metal/silica gel composition of U.S. Pat. No. 7,211,539and the Group 1 metal/porous metal oxide composition of U.S. Pat. No.7,259,128 (both of which are herein incorporated by reference in theirentirety) and others known in the art can be used. The aqueous solutioncan be a part of the reactor or can be introduced by an external supply.An external control system can be used to control the hydrogengeneration.

The performance of a fuel cell cartridge is based on how much hydrogenit can generate, which in turn is dependent in part on which reactantfuel material is used. As such, different reactant fuel material can beused depending on hydrogen production is necessary to meet the specifiedpower demand/requirement.

Sodium silicide (NaSi) is created through the reaction of sodium metalwith silicon powder and yields significantly more hydrogen per weightthan pure sodium or stabilized alkali metals. NaSi's hydrogen generationcapabilities are instantaneous and complete; it reacts instantaneouslywith any water solution to produce molecularly clean hydrogen gason-demand. The reaction with water produces 2.5 moles of hydrogen permole of NaSi according to the reaction:

2NaSi(s)+5H₂O(l)→5H₂(g)+Na₂Si₂O₅(aq)

NaSi is a useful source of hydrogen for fuel cells because it is lowweight, produces hydrogen on-demand, is air and temperature stable.Since hydrogen is not generated until water is added, this material canbe used, transported and stored safely, simply and indefinitely.

Sodium borohydride, NaBH₄ or “SBH”, produces hydrogen according to thereaction:

NaBH₄(s)+4H₂O(l)→4H₂(g)+NaBO₂*2H₂O(aq)

On a material's basis, NaBH₄ is energy dense with ˜21 wt. % hydrogen. Inpractice, however, much lower yields are realized due to the need forlarge amount of catalysts or stabilizers and the clogging of the waterways. Note: “wt %” refers to weight percent, which is the percent oftotal material mass that consists of hydrogen, and is a measure of thehydrogen density of a material used as a hydrogen source.

Pure NaSi can produce 9.8 wt % hydrogen on a material's basis. Wherepower requirements are low, pure NaSi may be used.

Where power requirements are higher (i.e., hydrogen density above 9.8 wt%), a NaSi/NaBH₄ hybrid as shown in FIG. 1 can be used in a standard50:50 wt % ratio to achieve up to 15.6 wt % hydrogen on a material'sbasis. An even a higher wt % H₂ can be produced if the hybridcomposition is altered to include more NaBH₄. The NaSi/NaBH₄ hybrid isthe standard composition of NaSi and NaBH₄:

2NaSi(s)+5H₂O(l)→5H₂(g)+Na₂Si₂O₅(aq)+ΔHNaSi

NaBH₄(s)+4H₂O(l)+ΔHNaSi→4H₂(g)+NaBO₂*2H₂O(aq)

The above equations are related to each other through the exothermicheat term. The NaSi hydrolysis reaction releases sufficient heat to bothdissociate hydrogen bonds in the injected water and promote rapidhydrolysis of the NaBH₄. The heavily localized area where this heatexchange occurs on the surface of NaSi particles, thus providing a“hotter” environment that is ideal for NaBH₄ dehydrogenation reactionconditions. This coupled reaction scheme is thus able to induce completehydrothermolysis of NaBH₄.

By combining the two materials, the best generation characteristics ofeach individual material is leveraged and high energy dense storage isachieved with instantaneous and self-sufficient hydrogen generationcharacteristics, as shown in FIG. 2. The hybrid also compensates for theshortcomings of each individual material by enhancing the hydride'sreaction rate while increasing hydrogen density. Each material's uniquegeneration characteristics are compared to that of the hybrid mix inFIG. 2. As illustrated, hydrogen generation with NaSi is near immediate,whereas NaBH₄ (also labeled as “SBH”) is capable of liberating morehydrogen on a per weight basis. Combined, the NaSi/NaBH₄ hybrid is bothquick to respond, self-regulated and longer sustained. Catalysts may beused in conjunction with the NaSi/NaBH₄ to promote and/or control thereaction.

Both chemicals individually liberate hydrogen via a hydrolysis reaction,but each sources the hydrogen differently. Whereas NaSi breaks andextracts hydrogen externally from the water, the hydrolysis of NaBH₄breaks hydrogen bonds internal to the compound. However, both materialsliberate hydrogen for use in a controlled manner solely proportional tothe rate of water injection. The directness of such an exchange (waterin=hydrogen out) simplifies the overall mechanical controls that areneeded in a hydrogen-generation system.

Water-usage to powder-usage may be reduced using the hybrid chemistry toresult in less volume required for water storage. For the same mass ofpowder, whether NaSi alone or a NaSi/NaBH₄ hybrid, both chemistriesutilize approximately the same water by weight. However, using thehybrid has repeatedly demonstrated a realistic 5 wt % H₂ increase ingeneration.

The powder fuel can be stored in the fuel cartridge in multiple physicalstorage factors to best accommodate reaction kinetics, dynamicstart/restart/stop responses, thermal management, or any otherparameters necessary for prime operation towards a specific applicationor system. This may involve alternation of particle diameter or formfactor of NaSi and/or NaBH₄, or further segregation of powdered fuel viamechanical dividers in each individual fuel compartment. The latterscenario may benefit a power system requiring a variable load and/orintermittent and rapid restarts. A power system providing continuous andsteady power delivery will simplify powder design and a cartridge cellfilled entirely with powder may be sufficient.

Anti-freeze salt additives may be added to the water reservoir, allowingthe use of the power system at below-freezing temperatures withoutcompromising overall reactivity

The water within each reactor may be placed within a water bladder,which will be surrounded by the reactant fuel. In this implementation,as the collapsible water bladder deflates with water depletion, thedisplaced water volume will be re-occupied by the newly-generated wastein the same allotted space. Aspects of this process are illustrated inFIG. 11, which shows a new cartridge on the left portion and a cartridgein operation on the right portion. A collapsible water bladder 1101 isinitially present in a reactor surrounded by a volume of fuel with aninternal water distribution network (not shown). During operation, waterfrom the collapsible water bladder 1101 is pumped via the fuel cell pump1103 out of the bladder and into the water distribution network thatevenly deposits water into the fuel bed. As water reacts with the fuel,waste is generated and re-occupies the volume of the displaced water asthe bladder shrinks. In operation, the reactor volume will containregions of waste 1104 and regions of fuel/H₂. This flexibility willprovide nearly unlimited form factor flexibility. Storage, transport andoperation are simplified as the major internal components (i.e., thereactant fuel and water storage) can be highly shape and volume pliable.Low (i.e., less than 5 psi) on-demand flow generation can be generated.This low operating pressure is important to the development of a “soft”system instead of one which must be contained within a hardened shell.

Water can be either added to the fuel cartridge in the field (via auser-fillable water compartment) or can be preloaded in each cartridgeat the factory. At the most basic level, the fuel cartridge may consistof a bed of hybrid fuel and a water distribution network that evenlydeposits water into the fuel bed. The distribution network may consistof small punched orifices in a flexible tube. The water spreaderconfiguration will be determined based on optimal reaction reach andspray, dependability, and the best balance between simplicity andfunctionality. In some exemplary implementations, fuel cell cartridgesmay be designed so that any water-reactive powder is within 0.7 inchesof a water inlet point. All structures can be integrated with passive oractive water controls with the option for water/waste exchange.

FIG. 13 illustrates aspects of a punching operation of a flexible tubesystem and an exemplary implementation of the same. The equipment takesa reel of tubing (not shown) and feeds the tubing strand 1301 into thecontrol head 1303 containing the punch rods 1302 for processing. Controlhead 1303 contains punch mechanisms 1304 that drive the punch rods 1302into the tubing strand to create small punched orifices 1305 in thetube. The finished, punched tubing is then re-wrapped onto another reel(not shown) for easy removal and storage.

In some implementations, the fuel cell or hydrogen cartridge can containfiltration elements to guarantee hydrogen purity upon delivery to thefuel cell or fuel cell system. Physical filtration may be necessary forretaining physical particulates, chemical foaming, and/or excessivemoisture. Chemical filtration may be necessary for scrubbing reactionbyproducts (both in liquid form carried by gas flow, or in gaseousform). A combination of the two will be incorporated into the cartridgeat locations to maximize exposure and engagement of the outlet hydrogengas. In this fashion, the most surface area would be available forfiltration to occur. In high humidity cartridges where excess watercannot be resolved by the methods above, condensing and or drieriteelements may be provided in the cartridge as well.

In one implementation, the fuel cell cartridge may generate 250 W-hr andis capable of hydrogen flow rates required for a 20 W load to enddevices.

Fuel cell cartridges can be made from a variety of materials to achievethe desired flexibility and conformability. Fuel cell cartridges canalso come in different shapes, thickness and sizes, and be treated withanti-corrosion substances such as silicate.

For example, FIG. 14 illustrates exemplary implementations of analuminum canister 1401 and a silicate-treated canister 1402.Silicate-treated canisters can retain structural soundness even in thepresence of corrosion due to optimal thickness. If aluminum canisterthickness is too large, after silicate corrosion, canisters can crumbleupon mechanical impact due to weakening aluminum thickness.

In some implementations, cartridges can be designed with an aluminumouter structure fuel cell cartridge of a thickness that will providestructure integrity up to 300 psi pressure and 100 kg load.

Fuel Cell System

The hydrogen generated from the fuel cell cartridge is delivered to thefuel cell system by any means known in the art. In the fuel cell system,the hydrogen reacts with oxygen to generate energy using any means knownin the art.

U.S. Patent Publication No. 2012/0115054, which is herein incorporatedby reference in its entirety, describes a portable water reactivehydrogen fuel cell power system comprising a fuel cell, a water feedtray system, and a fuel cartridge. In this system, water (or a liquidsolution) is combined with a powder to generate hydrogen for a fuel cellsystem. These reaction types can use a range of powders such as sodiumsilicide, sodium silica gel, sodium borohydride, sodium silicide/sodiumborohydride mixtures, aluminum, and others. Activators, catalysts, oradditives can be added to the powder to control water dispersion throughthe powder or water absorption of the reaction by-products. Additives tothe powder can also include defoamers, such as oils, as well as similarmaterials to distribute local reaction sites and/or temperatures toresult in a more uniform reactivity and heat distribution in the fuelcartridge and to control reaction conditions, including, for example,the chemical and physical nature of the reaction products andby-products. Powder size can be controlled to facilitate watertransport, reaction rate, and byproduct water absorption. Activators,catalysts, or other additives can also be added to the water in order toform a liquid solution at varying conditions.

The fuel cell system may include a PEM fuel cell stack rated at 25 Wgross output (20 W net after BOP losses and hybrid battery charging) andthe associated balance of plant (also referred to as “BOP”). The stackwill be hybridized with an integrated lithium-polymer battery in orderto ensure constant power output, to allow the system to handle hightransient loads, and to facilitate initial system start-up. The fuelcell system will also contain the sheet metal backplane, interfaces tothe fuel cell cartridge, and the fluid management subsystem needed togenerate hydrogen.

In exemplary implementations, the fuel cell subsystem may contain a5-cell PEM stack. With a 24-cell stack, the design can yield a rating of180 W continuous gross output. The 5-cell PEM stack may be capable of 25W gross output.

Exemplary implementations of fuel cell systems can further includevarious balance of plant components as shown in FIG. 9. A purge valve902 can be connected to the far end of fuel cell stack 904 anode flowfield. The fuel cell stack can be a 5 cell stack in someimplementations. When purge valve 902 is opened, hydrogen flows quicklythrough the stack 904 and clears out accumulated moisture that isdetrimental to stack operation. A stack air blower 910 can provide airfor cooling and reacting with the catalyst in the fuel cell. A systemcontroller PCB assembly 912 can be provided to monitor the fuel cellstack, operate the hydrogen generation subsystem, and operate the powerelectronics for management of internal battery charging, stack loadhandling and output switching/voltage set point. A heat sink 908 usesincoming stack air to cool the power electronics 906, which willdissipate waste heat during operation. A micropump 922 pulls water fromthe water bag and pushes it into the fuel selector valve block 920 withfuel selector valve 918. The fuel selector valve and valve blockswitcheswater delivery between the individual fuel modules. A hybrid Li-ionbattery 916 provides full output capability while the stack and hydrogengeneration subsystem are starting up and insulates the stack 904 frompeak power demands. An output/comms connector 914 connects output powerand SMBus communications to the electronic device being used. Fluidlines 924 deliver water from the water compartment to the micropump 922,water from the fuel selector valve block 920 to the fuel cartridges, andhydrogen from the fuel cartridge to the fuel cell stack 904. All fluidlines will route to the inside of the fuel cell subsystem and connect tothe control valve, fuel selector valve 918 and fuel cell stack 904.There will be no active components outside of the fuel cell subsystem.The parasitic load for the fuel cell system BOP can have consumed powernot exceeding an average of 5 W, resulting in 20 W net rated power. Thestorage battery 916 can supply additional power for short peaks andinstant total power during the startup times.

The Array of Fuel Cell Cartridges

In exemplary implementations, the fuel cell power systems can contain aplurality of fuel cell cartridges, each of which can be controlledindependently. An exemplary implementation of a flexible fuel cell powersystem with three fuel cell cartridges 504, a fuel cell system 506, anda platform 502, is illustrated in FIG. 5. A semi-flexible backplane 502is provided that can support the three fuel cell cartridges 504 andengage the cartridges at connection points 508 that can containinterface pins. The backbone material is also bent to provide theflanges 510 that support the fuel cell system and the fuel cellcartridges.

It has been discovered that a modular design with better hydrolysisperformance efficiency and start/stop capability can be better achievedin a smaller sized cartridge to minimize the maximum distance betweenthe water distribution network and any given particle of fuel. Eachmodule within a fuel cell cartridge may contain a flexible bag of thesilicide hybrid and a collapsible water bladder. As a fuel cartridge isdepleted it can be quickly replaced with a new cartridge. Cartridges maybe hot swappable, wherein a depleted cartridge may be replaced with afresh cartridge while the remaining one or more operating cartridgescontinue to provide fuel to the fuel cell. The cartridge design may alsoallow for the rapid replacement of fuel modules within a cartridge. Astate-of-charge display 401 as shown in FIG. 4 can allow users to seehow much fuel remains at any given time.

The flexibility of the segmented fuel cartridge will be achieved throughelastic deformation of flexible sheet metal members. Flexures andbendable support beams will be interwoven throughout the length of thefuel cartridge via the shared sheet metal backplane. This will allow thesystem to bend along one axis in a curvature that imitates the wearer'sbody.

The gaps between the segments at these flexible joints can be enclosedwith a bellows-type joint which will provide additional structuralsupport and prevent debris from entering the system. Each fuel modulewithin a cartridge can be operated either in a sequence orsimultaneously to facilitate control options, redundancy, and heatmanagement optimization in both warm and low temperature conditions. Ingeneral, it is anticipated that the control strategy will be to operateeach the fuel modules in a sequence in low temperature environments andin parallel in high temperature environments.

The water may be placed within a water bladder, which will be compressedagainst a fuel bag. In this form, the collapsible water bladder willdeflate as the water is depleted; the displaced water volume will thenbe re-occupied by the newly-generated waste (example: sodium silicate)in the same allotted space. One commonly shared water-fill-port may belocated on each fuel cartridge. This fill port can be used to fill allmodules in a single action. Air-inlet vents can be added to the fuelcell power system enabling air circulation through the fuel cartridgefor cooling.

The entire fuel cell cartridge may be covered in a flexible cartridgesheath. The outer casing may be constructed from a durable andthermally-resistant thick rubber, which will essentially mold itself tothe wearer's body without any pre-fixed mechanical feature. Metal orplastic ribs can be incorporated for additional support. A simpleconceptual diagram is shown in FIG. 7. In FIG. 7, a fuel cell system 701and fuel cell cartridge 702, comprised of multiple modules 703, 704, and705 are shown, with the cartridge covered in a flexible cartridgesheath.

Fuel Cell Power System

The fuel cell power system comprises the segmented fuel cell cartridgeconnected to the fuel cell system. An implementation of a basic fuelcell power system is shown in FIG. 8. A fuel cell system 802 can bedetachably connected to a fuel cartridge 804 which may be furthercomprised of multiple modules or may be a single module. In someimplementations, the fuel cell power system, the connected combinationof fuel cell system 802 and fuel cartridge 804, can have overalldimensions of approximately 6 inches by 0.7 inches by 9.45 inches.

Where there is a plurality of fuel cell modules making a cartridge, anexemplary implementation is shown in FIG. 3 and FIG. 6.

In FIG. 3, a segmented fuel cell cartridge 303 is shown with three fuelcell modules 304, 305, and 306. Modules may be hot swappable, wherein adepleted module may be replaced with a fresh module while the remainingone or more operating modules continue to provide fuel to the fuel cell.A fuel cell system 300 is shown with a state-of-charge indicator 302 andan electrical output port 301. FIG. 4 depicts a close-up view of animplementation of a state-of-charge indicator 401.

FIG. 6 shows an implementation of a flexible fuel cell power system,bending to a contoured shape. The integrated power system body includingthe fuel cell system and fuel cell cartridges 606, will be supported,for example on a 0.5 mm thick stainless steel backplane. As previouslydescribed, the backplane 601 is designed with flexures 602 between eachmodule to permit the system to bend. These flexures can handle roughly30 degrees of bending without permanent deformation. The backbonematerial is also bent to provide the flanges 604 that support the fuelcell system and the fuel cartridges. The top flanges can be designed toserve the function for quick and reliable latching and releasing thefuel cartridge. When a new fuel cartridge is fully installed, theinterface pins will penetrate seals for the water input and hydrogenoutput ports on each fuel module. Each fuel cartridge can be capable ofsupplying enough hydrogen for a net fuel cell output of, for example,more than 83 W-hr, yielding a total of 250 W-hr with all three fuelmodules in place.

The fuel cell power unit can include a data communications system thatconnects each module within the fuel cartridge to the fuel cellsubsystem. This will allow data to be collected, stored and communicatedto the user regarding the amount of hydrogen remaining in a cartridge,the number of restarts remaining, and specific module input valvecontrol.

For small, very low-power systems, a pressurized valve source can becombined with an on-off control valve. With this type of configuration,a stacked system is developed with individual key components compressedupon one another. For example, a rigid lid may be used to compress avolume consisting of (from the bottom up) a fuel pouch, water pouch,then a layer of foam rubber. This assembly enables direct injection ofwater from the water pouch above into the fuel pouch below via amechanical pressure differential applied by the compressed foam througha control valve. This passively operated planar system would be whollyself-sufficient, flexible, orientation independent (system is entirelycompressed during operation), and realistically scalable for multipleapplications. The compressed foam could also be easily replaced by anactive water injection method (such as the proposed) to allot more spacein the hydrogen generator cartridge itself.

While the passive method does eliminate the need for a mechanical pump,it affords less ability to control water, which becomes a moresignificant issue for a larger cartridge. A common water pump residingin the fuel cell system can be used for pumping water in the fuel cellcartridges, with each cartridge containing a controllable on/off valve.Alternatively, a miniature piezoelectric pump can also be used todeliver water into the fuel cell cartridges.

In an exemplary implementation, water can be pumped into thewater-reactive powder via a water distribution network atpre-established flow rate that is directly proportional to theanticipated hydrogen generation rate required by the desired fuel cellcurrent. A fuel selector valve can also be placed within the fuel cellmodule; this valve will be used to determine which fuel module to pumpwater to, enabling the system to operate the individual fuel moduleseither sequentially or simultaneously.

FIG. 10 shows aspects of an exemplary implementation of a fuel cellpower system. Fuel cell stack 1002 is connected to an H2 feed line 1004and purge valve 1006. Also depicted are H2 out interfaces 1014, water ininterfaces 1016, an H2 fail 1018 common to the interfaces with fuel cellcartridges (not shown), a fuel cartridge selector valve block 1008,micropump 1010, and water supply interface 1015.

As shown in FIG. 10, a single tube can connect all three watercompartments to the water pump 1010, and three separate tubes can beused to connect the selector valve to the fuel compartment within eachmodule. Water can be directed to flow to only one module at a time or toall modules simultaneously. The outward interfaces from each fuel modulecan connect to a common rail line that flows directly to the fuel cellstack. Check valves can be included in each module output interface toensure that there is no back flow into unused fuel. To establish adesign that fits achieves the energy density and lightweight, compactsystems requirements, all connectors and tubes can be incorporated intothe stainless steel backbone and travel down the length of the fuelcartridge body. The fuel and water interface components may featurealignment tabs that guarantee that each fuel module is properly alignedprior to the engagement of the interface needles.

When in use, a fuel cell cartridge snaps into place onto a locking tablocated on the backbone. Each fuel cell cartridge then is punctured bythe interface needles (as shown in FIG. 10) in a vertical motion. Thefuel cell cartridge can also be easily detached in the reverse motion.Since the fuel cell cartridges are engaged in parallel instead of inseries, removal of a depleted fuel module can be completed withoutinterrupting the flow of power delivery in a hot swappable system.

FIG. 12 illustrates silicide-based fuel cell power system that providessoldiers with a reliable source of portable power in a lightweight,rugged and conformal format. A fuel cell system 1201 is connected to afuel cartridge 1202. The cartridge 1202 is shown with multiple modules1203, 1204, and 1205. The modules may be used in concert orindividually. Different modules may be shut down or turned on dependingon the energy needs of the system. The system may also be dynamic and acontroller may turn on or off a particular module as needed. Modules maybe hot swappable, wherein a depleted module may be replaced with a freshmodule while the remaining one or more operating modules continue toprovide fuel to the fuel cell. This system includes a solidhydrogen-storage technology to create fuel cell power systems that arenon-flammable and non-explosive under stress, fire or ballistics. Thefuel cell power systems are light in weight and thin. Yet, the fuel cellpower systems generate enough power to potentially replace legacybattery technologies. The fuel cell power systems do not require batteryrecharging or new refueling infrastructures.

The fuel cell power systems of the present disclosure with all modulesoperating together can generate power up to 20 W, or up to 30 W.Preferably, the fuel cell power can generate power up to 35 W. Morepreferably, the fuel cell power can generate power up to 40 W.

The fuel cell power systems of the present disclosure can supply morethan 8 hours of power, or more than 10 hours of power. More preferably,the fuel cell power systems will supply more than 12 hours of consistentpower at 20 W for each 0.4 kg cartridge used.

The fuel cell power systems of the present disclosure can produce highenergy density for the fuel cell/cartridge combined. For example, thefuel cell power systems can generate 387 W-hr/kg at 646 g for at least12 hours of operation, or 531 W-hr/kg at 942 g for more than 24 hours ofoperation. Additionally, the energy density for additional cartridgescan be 616 W-hr/kg at 406 g including all fuel and water elements, witha development path to reach 1,140 W-hr/kg in a 235 g cartridge.

The fuel cell power system of the present disclosure may weigh less than1 kg, or less than 0.8 kg. Preferably, the fuel cell power system weighsless than 0.7 kg. More preferably, the fuel cell power system weighsless than 0.65 kg. The fuel cell power system is preferably lighter thana lithium battery power system. For example, in an exemplaryimplementation, the fuel cell power system is 942 g and 930 cc for a24-hour mission, representing a 77% reduction by weight and 64% byvolume from equivalent LI-145 batteries.

The fuel cell power system of the present disclosure offers a number ofother advantages, including long shelf life since the fuel does notdegrade over time and temperature.

Those of ordinary skill in the art will appreciate that a variety ofmaterials can be used in the manufacturing of the components in thedevices and systems disclosed herein. Any suitable structure and/ormaterial can be used for the various features described herein, and askilled artisan will be able to select an appropriate structures andmaterials based on various considerations, including the intended use ofthe systems disclosed herein, the intended arena within which they willbe used, and the equipment and/or accessories with which they areintended to be used, among other considerations. Conventional polymeric,metal-polymer composites, metal-matrix composites, ceramics, and metalmaterials are suitable for use in the various components. Materialshereinafter discovered and/or developed that are determined to besuitable for use in the features and elements described herein wouldalso be considered acceptable.

When ranges are used herein for physical properties, such as molecularweight, or chemical properties, such as chemical formulae, allcombinations, and subcombinations of ranges for specific exemplartherein are intended to be included.

The disclosures of each patent, patent application, and publicationcited or described in this document are hereby incorporated herein byreference, in its entirety.

Those of ordinary skill in the art will appreciate that numerous changesand modifications can be made to the exemplars of the disclosure andthat such changes and modifications can be made without departing fromthe spirit of the disclosure. It is, therefore, intended that theappended claims cover all such equivalent variations as fall within thetrue spirit and scope of the disclosure.

1. A portable flexible fuel cell power system comprising: a fuel cellcartridge comprising a plurality of fuel cell modules and a watercompartment, a fuel cell system, and a platform having bendable jointsor flexures which permit said platform to be flexible; a plurality ofconnection points configured to engage a plurality of fuel cell modulesand water compartments via a plurality of interface pins; wherein one ofthe plurality of connection points comprises a water supply interfaceconnected with a tube to a water pump, with the water compartmentconnected to the water supply interface; wherein two or more of theplurality of connection points each comprise an H₂-out interface pin anda water-in interface pin, with the plurality of fuel cell modulesconnected to the two or more connection points; wherein each water-ininterface pin is connected with a tube to a selector valve blockconfigured to control and direct the flow of water to the plurality offuel cell modules.
 2. The portable flexible fuel cell power system ofclaim 1, wherein the platform is conformable to mount around at least aportion of a person.
 3. The portable flexible fuel cell power system ofclaim 1, further comprising a common rail line connected to theplurality of H₂-out interface pins and configured to feed H₂ to the fuelcell system.
 4. The portable flexible fuel cell power system of claim 1,wherein said fuel cell cartridge or said plurality of fuel cell modulesare removably attached to said platform.
 5. The portable flexible fuelcell power system of claim 1, wherein one or more of said platform, saidfuel cell cartridge, said plurality of fuel cell modules, and said fuelcell system are constructed from flexible material.
 6. The portableflexible fuel cell power system of claim 5, wherein said flexiblematerial comprises polyethylene terephthalate.
 7. The portable flexiblefuel cell power system of claim 1, wherein said plurality of fuel cellmodules form a flexible fuel cartridge array connected by hinged orelastic joints.
 8. The portable flexible fuel cell power system of claim1, wherein said fuel cell cartridge comprises reactant fuel materialthat is NaSi or NaSi/NaBH₄ mixture.
 9. The portable flexible fuel cellpower system of claim 1, wherein said fuel cell system further comprisesone of more of the following: a purge valve, a stack air blower, asystem controller PCB assembly, a heat sink, a fuel selector, a hybridLi-ion battery, an output/comms connector, and one of more fluid lines.10. A method of supplying power via a conformable portable fuel cellpower system, the method comprising: providing a platform havingbendable joints, with a plurality of interfaces configured to connectwith removeable fuel cell modules and water components; wherein one ofthe interfaces is a water supply interface fluidly connected to a pump;and, wherein two or more interfaces comprise an H2-out interface and awater-in interface.
 11. The method of claim 10, the method furthercomprising a selector valve fluidly connected to a water-in interfaceand configured to control and direct the flow of water to a specificfuel cell module.
 12. The method of claim 10 wherein at least one of theplurality of fuel cell modules is hot swappable or removeable duringoperation of the fuel cell power system.